Electric fracturing truck cooling device, cooling system and cooling method

Abstract

The application discloses an electric drive fracturing vehicle cooling device, a cooling system and a cooling method, and belongs to the technical field of oil and gas exploitation equipment. The electric drive fracturing vehicle cooling device comprises a fan cover, a plurality of axial flow fans, a high-temperature expansion water tank, a low-temperature expansion water tank, a high-temperature circulating water radiator, a low-temperature circulating water radiator, a large-pump lubricating oil radiator and an intercooler. The high-temperature circulating water radiator, the low-temperature circulating water radiator and the large-pump lubricating oil radiator all adopt multi-plate fin type radiating modules. The engine, electrical components and hydraulic large pump are radiated through independent circulating loops, and the axial flow fans drive air to take away heat. The application adopts the multi-loop independent radiating and integrated structure design, the high-temperature and low-temperature circulating water loops independently operate, the intercooler and the large-pump lubricating oil radiator exchange heat by means of low-temperature cooling liquid, and the layout of the plate fin type radiating modules and the axial flow fans is matched, so that the radiating efficiency is improved, and the stable operation under high load is ensured.

Description

Technical Field

[0001] This invention relates to the field of oil and gas extraction equipment technology, specifically to a cooling device, cooling system, and cooling method for an electric fracturing truck. Background Technology

[0002] With the widespread application of electric fracturing skids in unconventional oil and gas extraction, the core high-power electric drive system generates enormous heat under high load and long-term operation, such as motors, frequency converters, and electronic control units.

[0003] The industry typically employs air cooling, liquid cooling, and combined cooling methods. However, as electric fracturing skids gradually replace traditional mechanically driven fracturing equipment, traditional cooling methods are no longer sufficient to meet the cooling requirements of core electric drive systems such as high-power motors, frequency converters, and electronic control units. To meet the cooling requirements of the vehicle's maximum heat output, cooling devices are designed based on the most severe operating conditions. This directly results in a huge system size, high airflow requirements, a large number of fans, and high energy consumption.

[0004] Existing forced air cooling solutions using aluminum brazed finned heat sinks suffer from insufficient heat exchange efficiency under harsh conditions such as high temperatures, high dust concentrations, and high-frequency equipment vibrations at mining sites. This makes it difficult to effectively dissipate the peak heat from the electric drive system, leading to overheating of core components and impacting equipment performance and reliability. Furthermore, the narrow fin spacing and weak connection strength make them prone to dust accumulation and blockage in high-dust environments, obstructing airflow channels and preventing the formation of insulation layers. Under high-frequency vibrations, they are susceptible to fatigue and detachment, not only completely losing their heat dissipation function but also potentially causing secondary equipment failures and posing safety hazards. This invention proposes a new solution to address these problems. Summary of the Invention

[0005] To overcome at least one of the aforementioned drawbacks, this invention provides a cooling device, cooling system, and cooling method for an electrically driven fracturing truck. The objective of this invention can be achieved by employing the following technical solutions: The first aspect of this application provides a cooling device for an electric fracturing truck, including a fan shroud, several axial flow fans, a high-temperature expansion tank, a low-temperature expansion tank, a high-temperature circulating water radiator, a low-temperature circulating water radiator, a large pump lubricating oil radiator, and an intercooler. The high-temperature circulating water radiator, the low-temperature circulating water radiator, and the large pump lubricating oil radiator all employ multi-fin cooling modules. Coolant is pumped into the engine water jacket to absorb heat generated by combustion, then enters the engine water radiator. The heat is dissipated to the outside air through the axial flow fans on the windward side. The cooled coolant is then circulated back to the engine. The high-temperature expansion tank and the high-temperature circulating water radiator form a high-temperature circulating water circuit for water replenishment, exhaust, and pressure balancing. Coolant flows through the generator and rectifier to absorb heat generated during operation before entering the motor. The heat dissipation module dissipates heat, and the cooled coolant returns to the heat-generating components. The low-temperature expansion tank and the low-temperature circulating water radiator form a low-temperature circulating water circuit, which is used to drive the coolant circulation with an independent water pump. The high-temperature and high-pressure intake air compressed by the turbocharger enters the intercooler. The high-temperature and high-pressure intake air exchanges heat with the flowing low-temperature coolant to reduce the intake air temperature and increase the air density. The large pump lubricating oil radiator is connected to the lubricating oil cooling circuit. The lubricating oil of the hydraulic large pump flows through the large pump lubricating oil radiator and exchanges heat with the flowing low-temperature coolant to reduce the oil temperature. The axial flow fan is installed in the fan shroud and is used to drive the cooling air to flow through the high-temperature circulating water radiator, the low-temperature circulating water radiator, the large pump lubricating oil radiator and the intercooler to dissipate heat to the outside air.

[0006] In one possible implementation, the low-temperature circulating water radiator and the large pump lubricating oil radiator are arranged on the same horizontal plane, and the low-temperature circulating water radiator and the large pump lubricating oil radiator are arranged below the high-temperature circulating water radiator in a superimposed arrangement with the high-temperature circulating water radiator.

[0007] In one possible implementation, the intercooler is disposed to the side of the high-temperature circulating water radiator, the low-temperature circulating water radiator, and the large pump lubricating oil radiator.

[0008] In one possible implementation, the flow path of the cooling air is configured as follows: the cooling air enters from the bottom and / or sides of the vehicle body, flows sequentially through the low-temperature circulating water radiator, the large pump lubricating oil radiator, the intercooler and the high-temperature circulating water radiator, and is then discharged from the top of the vehicle body after being driven by the axial flow fan.

[0009] A second aspect of this application provides a cooling system for an electric fracturing truck, including a control system and any of the electric fracturing truck cooling devices described in the first aspect. A plurality of electric fracturing truck cooling devices cover the core electric drive system of the electric fracturing truck. The control system is connected to the drive unit of the axial flow fan in each of the electric fracturing truck cooling devices, and is used to monitor the temperature of the core electric drive system of the electric fracturing truck, and independently adjust the start / stop status of each electric fracturing truck cooling device and the rotation speed of the axial flow fan according to real-time heat dissipation requirements.

[0010] In one possible implementation, the number of cooling devices in the electric fracturing truck is at least four, each covering a different heat-generating area or component of the core electric drive system.

[0011] In one possible implementation, the control system is equipped with a temperature sensor group and an operating condition identification module. The temperature sensor group is used to monitor the engine temperature, generator temperature, rectifier temperature, lubricating oil temperature, and intercooler outlet air temperature. The operating condition identification module is used to determine the current heat dissipation demand based on the feedback signal from the temperature sensor group and the engine load power, and generate control commands to send to each cooling device.

[0012] A third aspect of this application provides a cooling method for an electrically driven fracturing truck, applicable to any of the electrically driven fracturing truck cooling devices described in the first aspect, or applicable to any of the electrically driven fracturing truck cooling systems described in the second aspect. The steps of the electrically driven fracturing truck cooling method include: Acquire the current operating status signal of the electric fracturing truck, the operating status signal including at least engine load rate, ambient temperature and / or real-time temperature of core components; Based on the preset decision model, the total heat dissipation power required at present is determined based on the working status signal; Based on the required total heat dissipation power, dynamically start and stop at least one cooling device of the electric fracturing truck.

[0013] In one possible implementation, the decision model presets multiple heat dissipation power thresholds and corresponding module activation quantity strategies. When the total required heat dissipation power is determined to be lower than the first threshold, only one cooling device or part of the axial flow fan in one cooling device is activated. When the required total heat dissipation power reaches the maximum threshold, all axial flow fans of all cooling devices are activated.

[0014] In one possible implementation, during the operation of a single cooling device or multiple cooling devices, the rotational speed of the associated axial flow fan is independently adjusted by the control system according to the medium temperature of a specific circuit, so as to maintain the medium temperature within a preset target operating temperature range.

[0015] The beneficial technical effects of this invention are as follows: According to this disclosure, the cooling device, cooling system, and cooling method for the electric fracturing truck employ a multi-circuit independent heat dissipation and integrated structure. The high-temperature and low-temperature circulating water circuits operate separately, ensuring stable engine operation at a suitable temperature while precisely controlling the temperature rise of electrical components such as the generator and rectifier. The intercooler and the large pump lubricating oil cooler utilize low-temperature coolant to achieve intake air cooling and oil temperature control respectively, optimizing engine combustion efficiency and preventing hydraulic system failures. The integrated finned heat dissipation module and axial flow fan layout maximizes the utilization of the cooling airflow path, reducing heat generation. Accumulation ensures system stability under prolonged high-load operation. The cooling system consists of multiple cooling units and a control system. Multiple cooling units cover the core heat-generating area, and the control system monitors the temperature in real time and dynamically adjusts the start / stop and speed of the fans based on the operating conditions to achieve on-demand heat dissipation. It also has redundancy and reliability, so that the remaining units can continue to work when a single cooling unit fails. By collecting parameters such as engine load rate, ambient temperature, and core component temperature, the system analyzes and judges the total heat dissipation power through a preset decision model and dynamically starts and stops the cooling units to achieve intelligent temperature control and energy-saving operation. It is suitable for long-term high-load operation scenarios and improves system response speed and energy efficiency. Attached Figure Description

[0016] The following are given by way of example and without limitation in the accompanying drawings: Figure 1 A schematic diagram of the cooling system of the present invention is shown; Figure 2 A three-dimensional view of the cooling device of the present invention from one angle is shown; Figure 3 This shows a structural perspective view of the cooling device of the present invention from another angle; Figure 4 A top view of the cooling device of the present invention is shown; Figure 5 A front view of the cooling device of the present invention is shown; Figure 6 A schematic diagram of the high-temperature circulating water radiator and intercooler of the present invention is shown; Figure 7 A schematic diagram of the operation flow of the cooling method of the present invention is shown.

[0017] In the diagram: 100, Cooling device; 1, Fan cover; 2, Axial flow fan; 3, High temperature expansion tank; 4, Low temperature expansion tank; 5, High temperature circulating water radiator; 6, Low temperature circulating water radiator; 7, Large pump lubricating oil radiator; 8, Intercooler. Detailed Implementation

[0018] In the following detailed disclosure, these embodiments are fully described with reference to the accompanying drawings. In order to enable those skilled in the art to more clearly understand and comprehend the technical solutions of the present invention, the embodiments described below are not limited thereto. The present invention will be further described in detail below with reference to the embodiments and the accompanying drawings.

[0019] In this invention, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "install," "connect," "link," and "fix" should be interpreted broadly. For example, "connect" can be a fixed connection, a detachable connection, or an integral connection; "link" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0020] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "front," "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0021] The first aspect of this application, as Figures 2-7As shown, a cooling device for an electric fracturing truck is provided, including a fan shroud 1, several axial flow fans 2, a high-temperature expansion tank 3, a low-temperature expansion tank 4, a high-temperature circulating water radiator 5, a low-temperature circulating water radiator 6, a large pump lubricating oil radiator 7, and an intercooler 8. The high-temperature circulating water radiator 5, the low-temperature circulating water radiator 6, and the large pump lubricating oil radiator 7 all adopt multi-fin cooling modules. The coolant enters the engine water jacket via a water pump to absorb the heat generated by combustion, and then enters the engine water radiator. The heat is dissipated to the outside air through the airflow surface and the axial flow fans 2. The cooled coolant is then circulated back to the engine. The high-temperature expansion tank 3 and the high-temperature circulating water radiator 5 form a high-temperature circulating water circuit for water replenishment, exhaust, and pressure balancing. The coolant flows through the generator and rectifier to absorb the heat generated during operation. The coolant enters the motor cooling module for heat dissipation, and the cooled coolant returns to the heat-generating components. The low-temperature expansion tank 4 and the low-temperature circulating water radiator 6 form a low-temperature circulating water circuit, which is used to drive the coolant circulation with an independent water pump. The high-temperature and high-pressure intake air compressed by the turbocharger enters the intercooler 8. The high-temperature and high-pressure intake air exchanges heat with the flowing low-temperature coolant to reduce the intake air temperature and increase the air density. The large pump lubricating oil radiator 7 is connected to the lubricating oil cooling circuit. The lubricating oil of the hydraulic large pump flows through the large pump lubricating oil radiator 7 and exchanges heat with the flowing low-temperature coolant to reduce the oil temperature. The axial flow fan 2 is installed in the fan cover 1 and is used to drive the cooling air to flow through the high-temperature circulating water radiator 5, the low-temperature circulating water radiator 6, the large pump lubricating oil radiator 7 and the intercooler 8 to dissipate heat to the outside air.

[0022] The cooling device for the electric fracturing truck provided in this embodiment achieves precise temperature control of different heat-generating components through multi-circuit independent heat dissipation and integrated structural design, significantly improving overall heat dissipation efficiency. The high-temperature circulating water circuit and the low-temperature circulating water circuit operate independently, avoiding heat interference between coolants in different temperature ranges. This ensures stable engine operation at a suitable temperature and precisely controls the temperature rise of electrical components such as generators and rectifiers, effectively extending the service life of core components. The intercooler 8 and the large pump lubricating oil radiator 7 exchange heat with the low-temperature coolant, achieving intake air cooling and oil temperature control respectively. This not only optimizes engine combustion efficiency but also prevents lubrication failure or power loss in the hydraulic system due to excessively high oil temperature. The integrated plate-fin heat dissipation module and axial flow fan 2 layout design maximize the use of cooling air flow paths, allowing each heat dissipation element to fully exchange heat with the air, reducing heat accumulation inside the device, and ensuring continuous and stable operation of the entire cooling system under long-term high-load operation scenarios, thus improving cooling effect and efficiency.

[0023] The radiator assembly is connected to the vehicle compartment via a bracket at the bottom. The exhaust port and drain port are located at the highest and lowest points of the cooling system, respectively, depending on its installation position on the vehicle. The main mounting bracket for the cooling device 100 is made of channel steel or angle steel and uses a foot-mounted connection to ensure reliable connection.

[0024] The coolant heat absorption and circulating expansion tank provides coolant to the cooling device 100. The coolant first enters the engine, absorbing the large amount of heat generated during engine operation to maintain the engine at a suitable operating temperature. After absorbing heat, the high-temperature coolant then flows into the high-temperature circulating water radiator 5, where the axial flow fan 2 provides forced air cooling. The coolant dissipates heat into the environment through heat exchange with the outside air, completing the cooling process. The high-temperature expansion tank 3 performs the functions of system water replenishment, venting, and pressure balancing, ensuring that the main cooling circuit is always in a stable, cavitation-free operating state, maintaining the engine operating within its optimal operating temperature range.

[0025] The motor and rectifier cooling circuit is driven by an independent water pump to circulate the coolant. The coolant flows through components such as the generator and rectifier, absorbing the heat generated during their operation. It then enters the low-temperature circulating water radiator 6 for heat dissipation. The cooled coolant then returns to each heat-generating component, effectively controlling the temperature rise of the motor and rectifier, preventing insulation aging and overheating damage to components, and ensuring the continuous and stable output of the electrical system.

[0026] In this process, the air is first compressed by the turbocharger, which raises the air temperature. Then, it flows into the intercooler 8, where the high-temperature compressed air exchanges heat with the outside air or coolant, lowering the temperature. The cooled air then enters the engine and participates in the combustion process, providing the engine with sufficient, denser air, improving the engine's combustion efficiency and output power, while suppressing knocking tendencies and ensuring the power and reliability of the turbocharged engine.

[0027] The lubricating oil flows through the lubricating oil radiator 7 of the large pump, where it exchanges heat with the coolant to reduce the oil temperature. This prevents the oil viscosity from decreasing, lubrication from failing, and seals from aging due to excessively high oil temperature, thus maintaining good lubrication of the moving parts inside the large pump and ensuring stable output of pressure and flow in the hydraulic system.

[0028] The cooling device for the electric fracturing truck provided in this embodiment integrates the high-temperature circulating water radiator 5, the low-temperature circulating water radiator 6, the large pump lubricating oil radiator 7, and the intercooler 8, all sharing the same windward surface and cooling fan unit. This achieves centralized heat dissipation of engine coolant, motor coolant, large pump lubricating oil, and pressurized air. By optimizing the airflow and flow channel design, the overall heat dissipation efficiency is improved, while reducing system size and cost, thus meeting the heat dissipation needs of multiple heat sources in the entire machine.

[0029] Existing finned radiators have a heat exchange area of ​​only 80-120 m² / m³ per unit volume. In high-temperature environments above 40℃, due to temperature gradient compression, they struggle to quickly dissipate peak heat. Furthermore, the fins of finned radiators are mostly fixed with single-point welding, resulting in poor vibration resistance and a tendency to detach under high-frequency vehicle vibrations. The narrow fin spacing, typically only 2-3 mm, easily leads to dust accumulation and blockage, requiring frequent disassembly and cleaning. The fins are also prone to corrosion and detachment, resulting in a short service life.

[0030] This embodiment uses a plate-fin radiator as its core, rather than a traditional finned radiator. The plate-fin radiator, through its base plate and multi-layered dense fin structure, achieves a heat exchange area of ​​300-500 m² / m³ per unit volume. The corrugated or serrated fin design enhances airflow turbulence and improves the convective heat transfer coefficient. When the vehicle is under its most demanding operating conditions, such as full engine load with a heat output of 200 kW, the plate-fin modules work together to achieve a total heat exchange capacity of 250-300 kW. This not only meets the peak heat dissipation demand of 200 kW but also provides a certain degree of redundancy. Even in extreme high-temperature environments of 45°C, it can still maintain the engine temperature within the optimal range of 85°C-95°C through efficient heat exchange, preventing power degradation or insulation aging caused by high temperatures and ensuring the stable performance of core components. The fins, base plate, and cover plate of the plate-fin radiator are integrated using a brazing process, forming a complete rigid structure that improves connection strength. Furthermore, the multiple layers of fins support each other, forming a stable mechanical frame that disperses vibration stress and prevents localized fatigue damage. The fin spacing of the plate-fin radiator is optimized to 4mm-6mm, and the surface is coated with an anti-dust ceramic coating. It is made of corrosion-resistant aluminum alloy or stainless steel and has an integrated structure. Its service life can reach 5-8 years, which is 3-4 times that of traditional radiators. The comprehensive cost of the whole life cycle is reduced by more than 40% over 5 years. It is especially suitable for high-intensity operation scenarios such as mining and infrastructure, and significantly improves long-term economic efficiency.

[0031] In one possible implementation, such as Figure 5 and Figure 6 As shown, the low-temperature circulating water radiator 6 and the large pump lubricating oil radiator 7 are arranged on the same horizontal plane, and the low-temperature circulating water radiator 6 and the large pump lubricating oil radiator 7 are arranged below the high-temperature circulating water radiator 5 in a superimposed arrangement with the high-temperature circulating water radiator 5.

[0032] The high-temperature circulating water radiator 6, the large-pump lubricating oil radiator 7, the high-temperature circulating water radiator 5, and the intercooler 8 are integrated into a compact radiator assembly, which is placed horizontally in the upper middle part of the vehicle. The low-temperature circulating water radiator 6 and the large-pump lubricating oil radiator 7 are on the same horizontal plane, forming the lower basic structure of the radiator assembly; the high-temperature circulating water radiator 5 is stacked on top of the two, forming a layered layout; the intercooler 8 is independently arranged on the right side of the radiator assembly, forming a lateral cooperation with other heat dissipation components. The overall structure not only achieves efficient use of space, but also takes into account the functional independence of different heat dissipation circuits.

[0033] Understandably, from a thermal perspective, the high-temperature circulating water radiator 5, responsible for handling the high-temperature coolant generated by the engine, operates at the highest temperature. Placing it on the upper level allows for the utilization of the natural upward movement of hot air, accelerating heat dissipation and preventing thermal interference from the high-temperature airflow to the lower-temperature heat dissipation components. The lower-level low-temperature circulating water radiator 6 and the large-pump lubricating oil radiator 7 operate at relatively lower temperatures. Being on the same horizontal plane allows their low-temperature airflows to complement each other, reducing localized heat accumulation and improving overall heat dissipation efficiency.

[0034] Understandably, the upper middle part of a vehicle is usually a relatively spacious area with good airflow in the overall vehicle structure. Placing the radiator assembly flat here will not take up space under the chassis running gear, and will also avoid layout conflicts with components such as the cab and hydraulic pump assembly.

[0035] The fan unit is placed in the middle space of the radiator group, with the axial fan 2 on top. The axial fan 2 can directly draw hot air from above the radiator group, which has passed through the high-temperature circulating water heat exchanger, the low-temperature circulating water heat exchanger, the large pump lubricating oil radiator 7 and the intercooler 8, and quickly exhaust it outside the vehicle, forming an upward exhaust forced ventilation mode, which effectively avoids heat accumulation in the vehicle cabin.

[0036] Among them, the axial flow fan 2 is fixed to the bottom of the cooling compartment by the bracket, which enhances the rigidity and shock resistance of the overall device, and is especially suitable for the long-term operation of electric fracturing trucks under bumpy and high-vibration conditions in the field.

[0037] In one possible implementation, such as Figure 5 and Figure 6 As shown, the intercooler 8 is located to the side of the high-temperature circulating water radiator 5, the low-temperature circulating water radiator 6, and the large pump lubricating oil radiator 7.

[0038] The design of stacking the high-temperature circulating water radiator 5 and the low-temperature circulating water radiator 6 on top of each other and extending to the right side of the intercooler 8 fully utilizes space potential in both the longitudinal and lateral dimensions, allowing more heat dissipation components to be accommodated in a limited installation area, thus meeting the simultaneous heat dissipation requirements of multiple circuits in the electric fracturing truck. The side-mounted layout of the intercooler 8 keeps it away from the high-temperature core unit, enabling it to operate in a relatively independent low-temperature environment. This avoids the impact of high-temperature radiation on the intake air cooling effect, ensuring that the air entering the engine is always at a suitable temperature, thereby improving combustion efficiency.

[0039] In one possible implementation, the flow path of the cooling air is set as follows: the cooling air enters from the bottom and / or sides of the vehicle body, flows through the low-temperature circulating water radiator 6, the large pump lubricating oil radiator 7, the intercooler 8 and the high-temperature circulating water radiator 5 in sequence, and is then discharged from the top of the vehicle body after being driven by the axial flow fan 2.

[0040] The cooling device 100 provided in this embodiment operates by having external cooling air driven by a fan unit, which allows the cooling air to enter from the lower part and sides of the entire cabin, flow through the radiator, and then be discharged from the top to carry away heat. The cooling air first passes through the low-temperature circulating water radiator 6, the large pump lubricating oil radiator 7, and the intercooler 8, and then through the high-temperature circulating water radiator 5. The medium enters the radiator through pipelines and exchanges heat with the cooling air in the radiator, keeping the temperature of each medium within the normal operating range and ensuring the normal operation of the engine.

[0041] The cooling air enters the bottom of the vehicle from both sides of the wheels, flows into the upper part of the vehicle from the bottom, carries away the heat through the radiator, and is discharged from the top of the vehicle. This fully utilizes the heat absorption characteristics of air to carry away the heat generated by high and low temperature water, pressurized air, and large pump lubricating oil. At the same time, the discharged hot air will not affect pedestrians on the side of the vehicle.

[0042] Understandably, the counter-current principle of air cooling low-temperature components first and then high-temperature components allows the cooling air to gradually heat up during its flow, maximizing its temperature difference potential and improving heat exchange efficiency. The low-temperature circulating water radiator 6 and the large pump lubricating oil radiator 7, operating at lower temperatures, are positioned at the front of the airflow to obtain the lowest-temperature inlet airflow, ensuring stable operation of the generator, rectifier, and hydraulic system. The intercooler 8 follows closely behind, preventing excessively high inlet temperatures from affecting combustion efficiency. The high-temperature circulating water radiator 5 is located at the end of the airflow, handling the engine's high-temperature circuits. Even though the air is already warm, it effectively removes excess heat, preventing overheating of high-temperature components. The axial flow fan 2, positioned at the top, creates negative pressure suction, forcing the airflow vertically upwards, accelerating heat dissipation and preventing hot air from flowing back into the intake area, thus avoiding heat accumulation. This cooling airflow path is highly compatible with the layered stacking of the radiator assembly and the side-mounted intercooler 8, ensuring that heat dissipation in each circuit does not interfere with each other.

[0043] The second aspect of this application, as Figures 1-6 As shown, an electric fracturing truck cooling system is provided, including a control system and any one of the electric fracturing truck cooling devices in the first aspect. A plurality of electric fracturing truck cooling devices cover the core electric drive system of the electric fracturing truck. The control system is connected to the drive unit of the axial flow fan 2 in each electric fracturing truck cooling device to monitor the temperature of the core electric drive system of the electric fracturing truck and independently adjust the start / stop status of each electric fracturing truck cooling device and the speed of the axial flow fan 2 according to the real-time heat dissipation requirements.

[0044] The electric fracturing truck cooling system provided in this embodiment consists of multiple electric fracturing truck cooling devices and an integrated control system. The multiple cooling devices 100 are distributed above the core electric drive system, fully covering the main heat-generating areas to ensure that heat can be dissipated in a timely manner. The control system monitors the temperature data of the core electric drive system of the electric fracturing truck and performs comprehensive analysis in conjunction with the current working conditions to dynamically determine the heat dissipation needs of each area. It can independently control the start, stop and speed of the axial flow fan 2 in each cooling device 100 to achieve heat dissipation on demand, avoid energy waste, and prevent local overheating. This not only improves the system's response speed and adjustment accuracy but also enhances redundancy and reliability. Even if one cooling device 100 temporarily fails, the other cooling devices 100 can continue to work, ensuring the equipment can continue to operate under high-intensity operation.

[0045] In this application, the plate-fin module can be connected to different core components through independent pipelines, and the multi-channel structure of the plate-fin radiator supports independent circulation of coolant with different flow rates and temperatures; at the same time, each module is equipped with an independent temperature sensor and control unit, which can dynamically adjust the heat dissipation power according to the real-time temperature of the corresponding component, ensuring that each core component is always at the optimal operating temperature, extending the service life by 30%-50%, and improving the overall operational stability of the system.

[0046] The cooling system of the electric fracturing truck provided in this embodiment adopts a multi-module parallel design, which dissipates the heat of the entire engine and generator system through several sets of identical heat dissipation devices, ensuring that the entire engine and generator system is always at a suitable operating temperature, reducing energy consumption and improving the system's operational reliability.

[0047] In one possible implementation, such as Figure 1 As shown, the electric fracturing truck has at least four cooling devices, each covering a different heat-generating area or component of the core electric drive system.

[0048] The electric fracturing truck cooling system provided in this embodiment offers dynamic adjustment capabilities through a multi-cooling device 100 design. The plate-fin radiator provides efficient heat exchange and structural support, collaboratively solving the problems of low temperature control accuracy and poor adaptability in existing systems. Through multiple cooling devices 100 and a control system, precise zoned temperature control of the engine and generator systems is achieved, adapting to the differentiated needs of various components. The plate-fin modules can be connected to different core components via independent pipelines, and the multi-channel structure of the plate-fin radiator supports independent circulation of coolant at different flow rates and temperatures. Simultaneously, each cooling device 100 is equipped with an independent temperature sensor and control unit, which can dynamically adjust the heat dissipation power according to the real-time temperature of the corresponding component, ensuring that each core component is always at its optimal operating temperature, extending its service life, and improving the overall operational stability of the system.

[0049] like Figure 1 As shown, the cooling system can be composed of four identical heat dissipation devices connected in parallel. During operation, the number of modules activated can be adjusted according to environmental conditions and the power output of the engine and generator system. This not only ensures heat dissipation requirements under the most severe environmental conditions but also allows for flexible adjustment. When not all cooling devices 100 need to be activated, only some modules are activated, ensuring the system always operates at its optimal point. Each cooling device 100 is equipped with a radiator assembly and a fan assembly. Each fan assembly is controlled according to the water temperature through a control strategy, thereby changing the fan speed to ensure the entire vehicle system remains within the normal temperature range. This operating mode allows the electric fracturing truck to adapt to various environmental characteristics, especially seasonal transitions between winter and summer, and location changes between cold and hot regions. It can be adjusted according to the required heat dissipation, reducing energy loss and achieving system energy saving for the cooling device 100.

[0050] In existing technologies, to match peak heat dissipation demands, ultra-large single heat dissipation modules are typically used, resulting in a bulky system that encroaches on the installation space of other components in the vehicle chassis. These large single heat dissipation modules must operate at peak demand continuously, leading to significant energy waste even under light loads and normal driving conditions. Furthermore, a failure in a single large heat dissipation module can paralyze the entire cooling system, forcing the vehicle to shut down; moreover, the module's complex structure makes troubleshooting and repair difficult.

[0051] The cooling system provided in this embodiment, through the parallel arrangement of multiple miniaturized cooling devices 100, can reduce the volume of a single cooling device 100 to 1 / 4-1 / 3 of that of a traditional single heat dissipation module. Due to the high power density of the plate-fin radiator, a single cooling device 100 in this application still has efficient heat exchange capacity, and the cooling devices 100 can be distributed in the empty areas of the chassis, such as the sides of the frame and the gaps around the engine, avoiding the concentrated occupation of space by a single module. The number of cooling devices 100 activated can be dynamically adjusted according to real-time heat dissipation needs. When the vehicle is in a normal operating condition with low heat generation, only 1-2 sets of cooling devices 100 need to be activated to meet the heat dissipation needs, and the remaining cooling devices 100 are in standby mode. Only under severe operating conditions such as heavy-load climbing and high temperatures above 40°C are all 4 sets of cooling devices 100 activated to match peak heat dissipation needs. If a single cooling unit 100 fails, the remaining cooling units 100 can still work together. They can also dynamically adjust the fan speed and coolant flow to temporarily meet the heat dissipation requirements under normal operating conditions, avoiding emergency vehicle shutdown and buying time for repairs. At the same time, the single cooling unit 100 has a simple structure, and troubleshooting only requires targeting a single module, which improves repair efficiency and significantly reduces downtime losses caused by heat dissipation failures. In one possible implementation, the control system is equipped with a temperature sensor group and an operating condition identification module. The temperature sensor group is used to monitor the engine temperature, generator temperature, rectifier temperature, lubricating oil temperature, and intercooler 8 outlet air temperature. The operating condition identification module is used to determine the current heat dissipation demand based on the feedback signal from the temperature sensor group and the engine load power, and generate control commands to send to each cooling device 100.

[0052] The temperature sensor array monitors the temperature of key components such as the engine, generator, rectifier, lubricating oil, and air outlet of the intercooler 8 in real time. The operating condition identification module combines this data with the engine load power for comprehensive analysis to identify the current operating intensity and heat load trend. Based on this, the system can accurately determine whether it is operating under typical conditions such as high load, continuous operation, or low temperature start-up, and generate graded control commands accordingly. This dynamically adjusts the start / stop status and speed of the axial flow fans 2 in each cooling device 100, achieving a match between heat dissipation capacity and actual needs. This ensures that core components are always within a safe temperature range while avoiding energy waste caused by over-cooling.

[0053] The third aspect of this application, such as Figure 7 As shown, a cooling method for an electrically driven fracturing truck is provided, applicable to any of the electrically driven fracturing truck cooling devices in the first aspect, or applicable to any of the electrically driven fracturing truck cooling systems in the second aspect. The steps of the electrically driven fracturing truck cooling method include: Acquire the current operating status signal of the electric fracturing truck, which includes at least the engine load rate, ambient temperature and / or real-time temperature of core components; Based on the preset decision model, the total heat dissipation power required at the moment is determined based on the working status signal; Based on the required total heat dissipation power, dynamically start and stop at least one cooling device of the electric fracturing truck.

[0054] The cooling method for the electric fracturing truck provided in this embodiment achieves intelligent temperature control by acquiring working status signals, judging heat dissipation needs, and dynamically starting and stopping the cooling device 100. First, key parameters such as engine load rate, ambient temperature, and real-time temperature of core components are collected to comprehensively reflect the current thermal load status of the equipment. Then, the data is analyzed based on a preset decision model to accurately judge the total heat dissipation power required by the system, ensuring that the control strategy matches the actual working conditions. Finally, based on the judgment results, one or more cooling devices 100 are dynamically started and stopped to flexibly adjust the heat dissipation capacity, avoiding energy waste while ensuring that the core components are always within a safe temperature range. This achieves on-demand heat dissipation and energy-saving operation, which is suitable for long-term, high-load operation scenarios and significantly improves the response speed and energy efficiency of the cooling system.

[0055] In one possible implementation, the decision model presets multiple heat dissipation power thresholds and corresponding strategies for the number of modules activated. When the total required heat dissipation power is determined to be lower than the first threshold, only one cooling device 100 or part of the axial flow fan 2 in one cooling device 100 is activated; When the required total heat dissipation power reaches the maximum threshold, all axial flow fans 2 of all cooling devices 100 are started.

[0056] The decision-making model provided in this embodiment achieves refined energy efficiency management of the cooling system of the electric fracturing truck through a graded response mechanism. The model presets multiple heat dissipation power thresholds from low to high, each corresponding to a different activation strategy, ensuring that the heat dissipation capacity is accurately matched with the actual heat load. When the system determines that the required total heat dissipation power is lower than the first threshold, which typically corresponds to equipment idling, low-load operation, or low ambient temperature scenarios, the control system only activates one cooling device 100, or only activates part of the axial flow fan 2 within a single device, or the axial flow fan 2 operates at low speed or intermittently, significantly reducing fan energy consumption and noise, while avoiding energy waste caused by over-cooling and extending the service life of components. As the load increases and the heat dissipation demand crosses the intermediate threshold, the system gradually increases the number of activated cooling devices 100 or increases the speed of the already running fans, forming a stepped supplement to the heat dissipation capacity. When the required total heat dissipation power reaches the maximum threshold, typically corresponding to peak fracturing operations or extreme high-temperature environments, the control system will activate all cooling devices 100 and drive all axial flow fans 2 to operate at high speeds, forming a powerful forced ventilation and heat dissipation capacity. This ensures that the temperature of core electric drive components such as the engine, generator, and rectifier is always controlled within a safe range, preventing performance degradation or shutdown due to overheating. This threshold-based dynamic control strategy not only ensures heat dissipation reliability under all operating conditions but also significantly improves the vehicle's fuel economy and electrical system efficiency.

[0057] Among them, such as Figure 7 As shown, the power generation system provided in this embodiment uses a mechanical energy to electrical energy conversion system to drive a generator. The generator converts the input mechanical energy into alternating current (AC), which then enters a rectifier. The rectifier converts the AC into direct current (DC), providing stable DC power to the subsequent inverter-drive module. This module is equipped with multiple generators and rectifiers to meet the high power demands of load equipment such as large pumps. The DC power output from the rectifier is then sent to the inverter+drive module below. The inverter converts the DC power back into AC, and the drive module converts the electrical energy back into mechanical energy, ultimately driving the large pump and other load equipment.

[0058] Among them, such as Figure 7As shown, the cooling system provided in this embodiment generates a large amount of heat during the power conversion process of the generator and rectifier. Driven by a water pump, the coolant flows through the generator and rectifier, absorbing the heat generated, and then flows to the cooling device 100. In the cooling device 100, the coolant dissipates heat into the environment through heat exchange with the outside air, completing the cooling process. The cooled coolant is then driven by the water pump back to the generator and rectifier, continuing the heat dissipation cycle. This module, through the coordinated operation of power generation, rectification, and heat dissipation, ensures stable power output while effectively controlling the heat generated during power generation and rectification, ensuring stable operation of the motor and power generation system under high-temperature conditions. This provides reliable power support and thermal management for the entire system's power output and load drive.

[0059] like Figure 7 As shown, the composite cooling system for engine power and electric drive load provided in this embodiment achieves coordinated operation of power generation, thermal management and load drive through coolant circulation heat dissipation and power conversion and distribution. It is suitable for the complex working conditions of large-scale engineering equipment, such as fracturing skids and heavy machinery.

[0060] In one possible implementation, during the operation of a single cooling device 100 or multiple cooling devices 100, the rotational speed of the associated axial flow fan 2 is independently adjusted by the control system according to the medium temperature of a specific circuit, so as to maintain the medium temperature within a preset target operating temperature range.

[0061] In the operation of the cooling system of the electric fracturing truck, the control system employs a closed-loop feedback mechanism to independently and precisely regulate the axial flow fan 2. The system collects real-time temperature signals of the media in specific loops, such as high-temperature circulating water, low-temperature circulating water, lubricating oil, and air outlet of the intercooler 8, and compares them with preset target operating temperature ranges. When the temperature of a certain loop exceeds the upper limit of the target range, the control system gradually increases the speed of the corresponding axial flow fan 2 to enhance forced ventilation and accelerate heat dissipation; conversely, when the temperature is below the lower limit of the target range, the fan speed is reduced or operation is suspended to reduce energy consumption and prevent overcooling. This independent adjustment strategy based on real-time temperature ensures that each heat dissipation loop maintains optimal thermal balance, avoiding performance degradation due to local overheating and optimizing overall energy efficiency, significantly improving the operational stability, economy, and reliability of the electric fracturing truck under complex working conditions.

[0062] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0063] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A cooling device for an electrically driven fracturing truck, characterized in that, The system includes a shroud (1), several axial flow fans (2), a high-temperature expansion tank (3), a low-temperature expansion tank (4), a high-temperature circulating water radiator (5), a low-temperature circulating water radiator (6), a large pump lubricating oil radiator (7), and an intercooler (8). The high-temperature circulating water radiator (5), the low-temperature circulating water radiator (6), and the large pump lubricating oil radiator (7) all adopt multi-fin cooling modules. The coolant enters the engine water jacket through the water pump to absorb the heat generated by combustion and then enters the engine water radiator. The heat is dissipated to the outside air through the windward side and the axial flow fans (2). The cooled coolant is then circulated back to the engine. The high-temperature expansion tank (3) and the high-temperature circulating water radiator (5) form a high-temperature circulating water circuit for water replenishment, exhaust, and pressure balance. The coolant flows through the generator and rectifier to absorb the heat generated during operation and then enters the motor cooling module for heat dissipation. The cooled liquid returns to the heat-generating components after being heated and cooled. The low-temperature expansion tank (4) and the low-temperature circulating water radiator (6) form a low-temperature circulating water circuit, which is used to drive the coolant circulation with an independent water pump. The high-temperature and high-pressure intake air compressed by the booster enters the intercooler (8). The high-temperature and high-pressure intake air exchanges heat with the low-temperature coolant flowing through it to reduce the intake air temperature and increase the air density. The large pump lubricating oil radiator (7) is connected to the lubricating oil cooling circuit. The lubricating oil of the hydraulic large pump flows through the large pump lubricating oil radiator (7) and exchanges heat with the low-temperature coolant flowing through it to reduce the oil temperature. The axial flow fan (2) is installed in the fan cover (1) and is used to drive the cooling air to flow through the high-temperature circulating water radiator (5), the low-temperature circulating water radiator (6), the large pump lubricating oil radiator (7) and the intercooler (8) to dissipate heat to the outside air.

2. The cooling device for the electrically driven fracturing truck according to claim 1, characterized in that, The low-temperature circulating water radiator (6) and the large pump lubricating oil radiator (7) are arranged on the same horizontal plane. The low-temperature circulating water radiator (6) and the large pump lubricating oil radiator (7) are arranged below the high-temperature circulating water radiator (5) and are arranged in a superimposed structure with the high-temperature circulating water radiator (5).

3. The cooling device for the electric fracturing truck according to claim 2, characterized in that, The intercooler (8) is located on the side of the high-temperature circulating water radiator (5), the low-temperature circulating water radiator (6), and the large pump lubricating oil radiator (7).

4. The cooling device for an electrically driven fracturing truck according to any one of claims 1-3, characterized in that, The flow path of the cooling air is set as follows: the cooling air enters from the bottom and / or sides of the vehicle body, flows through the low temperature circulating water radiator (6), the large pump lubricating oil radiator (7), the intercooler (8) and the high temperature circulating water radiator (5) in sequence, and is discharged from the top of the vehicle body after being driven by the axial flow fan (2).

5. A cooling system for an electrically driven fracturing truck, characterized in that, The system includes a control system and a cooling device for an electric fracturing truck as described in any one of claims 1-4. Several cooling devices for electric fracturing trucks cover the core electric drive system of the electric fracturing truck. The control system is connected to the drive unit of the axial flow fan (2) in each of the electric fracturing truck cooling devices. The control system is used to monitor the temperature of the core electric drive system of the electric fracturing truck and independently adjust the start / stop status of each electric fracturing truck cooling device and the rotation speed of the axial flow fan (2) according to the real-time heat dissipation requirements.

6. The cooling system for the electric fracturing truck according to claim 5, characterized in that, The electric fracturing truck has at least four cooling devices, each covering a different heat-generating area or component of the core electric drive system.

7. The cooling system for the electric fracturing truck according to claim 1, characterized in that, The control system is equipped with a temperature sensor group and an operating condition identification module. The temperature sensor group is used to monitor the engine temperature, generator temperature, rectifier temperature, lubricating oil temperature and intercooler (8) outlet air temperature. The operating condition identification module is used to determine the current heat dissipation demand based on the feedback signal of the temperature sensor group and the engine load power, and generate control commands to send to each cooling device (100).

8. A cooling method for an electrically driven fracturing truck, characterized in that, The cooling method for an electric fracturing truck, applicable to any one of claims 1-4 or to any one of claims 5-7, comprises the following steps: Acquire the current operating status signal of the electric fracturing truck, the operating status signal including at least engine load rate, ambient temperature and / or real-time temperature of core components; Based on the preset decision model, the total heat dissipation power required at present is determined based on the working status signal; Based on the required total heat dissipation power, dynamically start and stop at least one cooling device of the electric fracturing truck.

9. The cooling method for an electrically driven fracturing truck according to claim 8, characterized in that, The decision model presets multiple heat dissipation power thresholds and corresponding module activation quantity strategies. When the total required heat dissipation power is determined to be lower than the first threshold, only one cooling device (100) or part of the axial flow fan (2) in one cooling device (100) is started. When the required total heat dissipation power reaches the maximum threshold, all axial flow fans (2) of all cooling devices (100) are started.

10. The cooling method for an electrically driven fracturing truck according to claim 8 or 9, characterized in that, During the operation of a single cooling device (100) or multiple cooling devices (100), the speed of the associated axial flow fan (2) is independently adjusted by the control system according to the medium temperature of the specific circuit, so as to maintain the medium temperature within the preset target operating temperature range.

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